Sign up to receive free email alerts when patent applications with chosen keywords are publishedSIGN UP

Abstract:

A waterproof breathable material has a higher strength-to-weight ratio
and higher tear resistance-to-weight ratio than traditional materials,
and may be applied in a wide field of potential uses. A non-woven
composite material comprises at least one waterproof breathable (W/B)
membrane, a first unidirectional non-woven composite layer having
multiple fibers enclosed by adhesive in parallel to each other, a second
unidirectional non-woven composite layer having multiple fibers enclosed
in adhesive in parallel to each other. The first unidirectional non-woven
composite layer is positioned such that the fibers are oriented
90° relative to the fibers of the second unidirectional non-woven
composite layer, and a space is formed between the first and second
multiple fibers. No adhesive is present in the space.

Claims:

1. A non-woven composite material comprising: at least one waterproof
breathable (W/B) membrane; and at least one unidirectional non-woven
composite layer comprising multiple fibers in parallel to each other,
wherein the multiple fibers are enclosed by an adhesive; wherein the
multiple fibers of the at least one unidirectional non-woven composite
layer are arranged in parallel such that a space is formed between the
multiple fibers, and wherein the space is absent adhesive.

2. A non-woven composite material comprising: at least one waterproof
breathable (W/B) membrane; a first unidirectional non-woven composite
layer comprising first multiple fibers in parallel to each other, wherein
the first multiple fibers are enclosed by an adhesive; a second
unidirectional non-woven composite layer comprising second multiple
fibers in parallel to each other, wherein the second multiple fibers are
enclosed by an adhesive; wherein the first unidirectional non-woven
composite layer is positioned such that the first multiple fibers are
oriented 90.degree. relative to second multiple fibers of the second
unidirectional non-woven composite layer; and wherein a space is formed
between the first and second multiple fibers, and wherein the space is
absent adhesive.

3. A non-woven composite material comprising: at least one waterproof
breathable (W/B) membrane; a first unidirectional non-woven composite
layer comprising first multiple fibers in parallel to each other, wherein
the first multiple fibers are enclosed by an adhesive; a second
unidirectional non-woven composite layer comprising second multiple
fibers in parallel to each other, wherein the second multiple fibers are
enclosed by an adhesive; a third unidirectional non-woven composite layer
comprising third multiple fibers in parallel to each other, wherein the
third multiple fibers are enclosed by an adhesive; wherein the first
unidirectional non-woven composite layer is positioned such that the
first multiple fibers are oriented 90.degree. relative to second multiple
fibers of the second unidirectional non-woven composite layer; wherein
the third unidirectional non-woven composite layer is positioned such
that the third multiple fibers are oriented 45.degree. relative to second
multiple fibers of the second unidirectional non-woven composite layer;
wherein a space is formed between the first, second, and third multiple
fibers, and wherein the space is absent adhesive.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a non-provisional of U.S. Patent Application
No. 61/358,394, filed Jun. 24, 2010, and entitled "WATERPROOF BREATHABLE
COMPOSITE MATERIALS FOR FABRICATION OF FLEXIBLE MEMBRANES AND OTHER
ARTICLES", and this application is also a non-provisional of U.S. Patent
Application No. 61/370,448, filed Aug. 3, 2010, and entitled "SYSTEM AND
METHOD FOR COLOR TRANSFER TO LAMINATE COMPOSITE MATERIALS AND OTHER
ARTICLES", both of which are hereby incorporated by reference.

FIELD OF THE INVENTION

[0002] The application relates to Waterproof Breathable materials,
particularly to an improved Waterproof Breathable material for a variety
of uses and applications.

BACKGROUND OF THE INVENTION

[0003] In the prior art, a lamination process is used to bond Waterproof
Breathable ("W/B") films or membranes (typically manufactured from PTFE
or PU) to woven fabrics. The purpose of the woven materials, typically
nylon or polyester, is to provide material properties, such as strength,
stretch resistance and tear resistance to the laminate. The problem with
the resulting W/B woven materials and randomly oriented non-woven W/B
materials is that their heavy weight, low strength-to-weight ratio,
excessive thickness and low tear resistance and rip stop properties
limits the material's usefulness. Thus, a need exists for a material
having a higher strength-to-weight ratio and higher tear
resistance-to-weight ratio that may be applied in a wide field of
potential uses.

SUMMARY OF THE INVENTION

[0004] A waterproof breathable material has a higher strength-to-weight
ratio and higher tear resistance-to-weight ratio than traditional
materials, and may be applied in a wide field of potential uses. A
non-woven composite material comprises at least one waterproof breathable
(W/B) membrane, a first unidirectional non-woven composite layer having
multiple fibers enclosed by adhesive in parallel to each other, a second
unidirectional non-woven composite layer having multiple fibers enclosed
in adhesive in parallel to each other. The first unidirectional non-woven
composite layer is positioned such that the fibers are oriented
90° relative to the fibers of the second unidirectional non-woven
composite layer, and a space is formed between the first and second
multiple fibers. No adhesive is present in the space.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] A more complete understanding of the present invention may be
derived by referring to the detailed description and claims when
considered in connection with the Figures, where like reference numbers
refer to similar elements throughout the Figures, and:

[0006] FIG. 1 illustrates an exemplary embodiment of a woven material
having one-directional reinforced construction; and

[0009] FIG. 4 illustrates an exploded view of an exemplary embodiment of a
woven material having four-directional reinforced construction and a bias
ply reinforcement layer and a fabric top layer;

[0010]FIG. 5 illustrates an exemplary embodiment of a woven material
having one-directional reinforced construction with a non-W/B polymer
coating the fibers and embedded in a W/B polymer;

[0011] FIG. 6 illustrates an exemplary embodiment of a woven material
having one-directional reinforced construction with a non-W/B polymer
coating the fibers and embedded in a W/B polymer; and bonded to a W/B
membrane;

[0012] FIG. 7 illustrates an exemplary embodiment of a woven material
having one-directional reinforced construction with the fibers embedded
in a W/B polymer;

[0013] FIG. 8 illustrates an exemplary embodiment of a woven material
having one-directional reinforced construction with the fibers embedded
in a W/B polymer and bonded to a W/B membrane;

[0014] FIG. 9 illustrates an exemplary embodiment of a woven material
having four-directional reinforced construction with the fibers embedded
in a W/B polymer; and

[0015] FIG. 10 illustrates an exemplary embodiment of a woven material
having four-directional reinforced construction with the fibers embedded
in a W/B polymer and bonded to a W/B membrane.

DETAILED DESCRIPTION OF THE INVENTION

[0016] While exemplary embodiments are described herein in sufficient
detail to enable those skilled in the art to practice the invention, it
should be understood that other embodiments may be realized and that
logical material, assembly, and mechanical changes may be made without
departing from the spirit and scope of the invention. Thus, the following
detailed description is presented for purposes of illustration only.

[0017] Waterproof Breathable composite materials provide the next
generation in lightweight, high strength, flexible, Waterproof Breathable
("W/B") materials. In an exemplary embodiment, a W/B membrane (such as
PTFE or urethane W/B material) is bonded to a Composite Material. As used
herein, Composite Material is defined as one or more layers of
unidirectional fiber and polymer matrix plies oriented in one or more
directions. These membranes may be either waterproof but porous to gas
and water vapor flow or they may be non porous but allow water vapor to
move through the material via diffusion. In an exemplary embodiment, the
Composite Materials are made from thinly spread high strength fibers such
as Dyneema®, Vectran®, Aramid, polyester, other materials that
are coated with adhesive or other material, or any combination thereof.
The adhesive or other polymer used may be a W/B type of urethane polymer,
though other non-urethane W/B materials or non-urethane non-W/B materials
may also be suitable. The advantage of the exemplary Composite Materials
is that the manufactured materials can be significantly thinner, more
flexible, have better touch and feel characteristics, and are lighter
than woven and randomly oriented nonwoven materials without sacrificing
strength or other material properties. In an exemplary embodiment, a W/B
Composite Material has a higher strength-to-weight ratio and tear
resistance than other flexible W/B materials currently available on the
market. Additionally, the exemplary Composite Material have limited
impact on the breathability of the membrane because the areas between the
fiber filaments, monofilaments, threads or tows are either free from gas
permeability blocking polymer or contain a permeable W/B adhesive or film
which allows gas breathability while preventing or inhibiting the flow of
fluids. Tows are a fiber bundle with a plurality of monofilaments. The
W/B membrane may or may not incorporate unidirectional reinforcing
filaments, fibers, or tows.

[0018] In an exemplary embodiment and with reference to FIG. 1, a
non-woven layered composite 100 comprises at least one layer that is a
W/B membrane 101 and at least one other layer that is a unidirectional
non-woven composite 102. In one embodiment, non-woven composite 102
comprises multiple fibers 111 in parallel with each other. The fibers 111
are enclosed by adhesive 112 that forms a cover. Furthermore, fibers 111
of non-woven composite 102 are arranged such that spaces form that are
adhesive-free zones 120. However, other suitable configurations of the
non-woven layered composite material are also contemplated.

[0019] In another exemplary embodiment and with reference to FIG. 2, a
non-woven W/B composite material 200 comprises at least one W/B membrane
layer 201, a first unidirectional non-woven composite 202, and a second
unidirectional non-woven composite 203. Similar to non-woven composite
102, non-woven composites 202, 203 individually comprise multiple fibers
211 in parallel with each other. The fibers 211 are enclosed by adhesive
212 that forms a cover. Moreover, non-woven composite 202 and non-woven
composite 203 are oriented such that the respective fibers 211 are
rotated 90° relative to the adjacent layer of fibers 211. This
cross-hatch configuration of non-woven W/B composite material 200 forms
spaces 220 through the layers that are adhesive-free zones.

[0020] In yet another exemplary embodiment and with reference to FIG. 3, a
non-woven W/B composite material 30 comprises at least one W/B membrane
layer 31, a first unidirectional non-woven composite 302, a second
unidirectional non-woven composite 303, and a third unidirectional
non-woven composite 304. Similar to non-woven composites 102, 202, and
203, non-woven composites 302, 303, 304 individually comprise multiple
fibers 311 in parallel with each other. The fibers 311 are enclosed by
adhesive 312 that forms a cover. Moreover, non-woven composite layers
302, 303, 304 are oriented such that the respective fibers 311 are
rotated 45° or 90° relative to the adjacent layer of fibers
311. This additional cross-hatch configuration of non-woven W/B composite
material 300 forms spaces 320 through the layers that are adhesive-free
zones. As is illustrated in FIG. 3, the adhesive-free zone spaces 320 in
non-woven W/B composite material 300 are more restricted than in
non-woven W/B composite material 200 due to the additional layer of
overlap and additional off-set angle of the fibers 311.

[0021] Furthermore, in an exemplary embodiment, the material layers are
combined and cured together using pressure and temperature either by
passing the stacked layers through a heated set of nips rolls, a heated
press, a heated vacuum press, a heated belt press or by placing the stack
of layers into a vacuum lamination tool and exposing the stack to heat.
Moreover, external pressure, such as provided by an autoclave, may also
be used to increase the pressure exerted on the layers. The vacuum
lamination tool may be covered with a vacuum bag sealed to the lamination
tool with a vacuum applied to provide pressure. Other lamination methods
may also be suitable as would be known to one skilled in the art.

[0022] The W/B composite material functions as a high strength-to-weight
ratio barrier layer that permits the transfer of gas, including water
vapor, through the materials but not the transfer of liquid water.
Furthermore, in various embodiments, the exemplary W/B composite material
may be used in but not limited to: sleeping bag shells, tent walls, and
clothing. In one embodiment, a Composite Material, such as a
unidirectional fiber reinforced tape, is bonded to a W/B membrane. A
preferred embodiment of the exemplary material would be material
consisting of an eVent W/B membrane bonded on one surface to Cubic Tech
product CT1, thus creating a Cubic Tech product CTB1B3/NF. Various
embodiments may include other configurations of W/B membranes, woven and
non-woven fabrics and other materials produced by Cubic Tech.

[0023] In a first exemplary embodiment, one or more layers of a W/B
membrane are bonded to both outer surfaces of a Cubic Tech laminate. The
laminate may be of various different product weights, strengths, colors,
and patterns. In a second exemplary embodiment, the Composite Material
includes coloration of the matrix or membranes through use of pigments or
dye sublimation. In a third exemplary embodiment, a fire retardant
adhesive or polymer is used, or fire retardants can be added to a
flammable matrix or membrane to improve the flame resistance. Examples of
fire retardant additives include: DOW D.E.R. 593 Brominated Resin, Dow
Corning 3 Fire Retardant Resin, and polyurethane resin with Antimony
Trioxide (such as EMC-85/10A from PDM Neptec ltd.), although other fire
retardant additives may also be suitable. Fire retardant additives that
may be used to improve flame resistance include Fyrol FR-2, Fyrol HF-4,
Fyrol PNX, Fyrol 6, and SaFRon 7700, although other additives may also be
suitable. Fire retardancy and self extinguishing features can also be
added to the fibers either by using fire retardant fibers such as Nomex
or Kevlar, ceramic or metallic wire filaments, direct addition of fire
retardant compounds to the fiber formulation during the fiber
manufacturing process, or by coating the fibers with a sizing, polymer or
adhesive incorporating fire retardant compounds listed above or others as
appropriate. Any woven or scrim materials used in the laminate may be
either be pretreated for fire retardancy by the supplier or coated and
infused with fire retardant compounds during the manufacturing process.

[0024] In a fourth exemplary embodiment, the material further comprises
hybrid layup plys or hybrid stacks to modify or improve various
mechanical properties of the material. Hybrid plys are defined as the
usage of at least 2 (two) non-matrix elements (various fiber types, wire,
meshes, etc) within a single ply that make up the composite. A hybrid
stack is defined as the usage of unique separate plys, each containing at
least 1 (one) non-matrix element that is different than at least one
adjacent ply. The non-matrix element, for example, may be various fiber
types, fiber coated or plated with metals or oxides, wire monofilaments,
wire meshes, and the like. In a fifth exemplary embodiment, a composite
W/B material comprises a woven or non-woven cloth or leather on one or
both sides. In a sixth exemplary embodiment, the W/B composite comprises
a compatible adhesive on one or both sides for lamination to third party
fabrics (woven, nonwoven, leathers) to upgrade the strength, tear
resistance (rip stop) and add W/B properties to the third party fabrics.
In a seventh embodiment, the W/B composite further adds
anti-microbial/anti-pathogen resistance by the incorporation of one or
more if anti-microbial agents added or coated onto the polymer resins,
film or fabrics, and anti-microbial treatments to the fibers,
monofilaments, threads or tows used for composite material. Typical
materials include OxiTitan Antimicrobial, and nana silver compounds,
Sodium pyrithione, Zinc pyrithione 2-Fluoroethanol,
1-Bromo-2-fluoroethane, Benzimidazole, Fleroxacin, 1,4-Butanedisulfonic
acid disodium salt, 2-(2-pyridyl)isothiourea N-oxide hydrochloride,
Quarternary ammonium salt, 2-Pyridinethiol 1-oxide, Compound zinc
pyrithione, Compound copper pyrithione, magnesium pyrithione,
BISPYRITHIONE, pyrithione, α-Bromo Cinnam-Gel, KFO ABC Silica Gel
manufactured. Fiber forms such as threads, tows and monofilaments can be
treated with silver nano particles, or can have silver coatings applied
via chemical or electrical plating, vacuum deposition or coating with a
silver compound containing polymer, adhesive or sizing. The
anti-microbial/anti-pathogen materials may also be suitable.

[0025] Traditional W/B materials are constructed or laminated to woven
base fabrics. In contrast, in an exemplary embodiment and with reference
to FIG. 4, a W/B Composite Material 400 may comprise at least one layer
of fibers 402, 403, 404, 405 bonded to at least one of a first membrane
layer 401 and a second membrane layer 406. Fibers 402, 403, 404, 405 may
be either a membrane or a fabric layer. Layers 401, 406 may be either
membranes, fabric layers, or ply reinforcement layers. In some
embodiments, only a single membrane or fabric layer is included. In
another exemplary embodiment, a W/B composite material comprises only
reinforced fiber plies, and excludes one or both membrane or fabric
layers. In an exemplary embodiment, at least one layer of fibers is a
flexible non-woven composite made from unidirectional fiber/matrix tape.
Furthermore, at least one type of fiber may comprise a single fiber layer
or multiple fiber layers. In addition, the fiber layers can be at any
orientation relative to other fiber layers. For example, FIG. 2
illustrates two layers of fibers with orientations of 0° and
90° relative to an axis in a membrane layer. FIGS. 3 and 4
illustrate exemplary embodiments of four layers of fibers with
orientations of 0°, 90°, -45°, and +45°
relative to an axis in a membrane layer. The spread fibers are arranged
such that the fiber's filaments form "windows" facilitating breathability
and gas permeability. In other words, the filaments have a controlled
spacing that results in gaps between the filaments of each fiber layer
and the gaps of each fiber layer align with fiber filament gaps of the
adjacent fiber layer to form a pass-through hole (window). In one
embodiment, the filament spacing in each fiber layer may be in the range
of about one micrometer to about one centimeter. In accordance with an
exemplary embodiment, the size of the gas permeable filament window is at
least as large as the pores in the W/B membrane. The filament windows and
the pores in the W/B membrane allow gas or water vapor to transfer
through the material. In other words, an exemplary Composite Material
creates grids of "windows" between the filaments, which in turn creates a
semi-porous material.

[0026] A W/B Composite Material comprising a unidirectional fiber/matrix
tape may utilize a resin or other adhesive to bond the materials
together. In accordance with an exemplary embodiment, the flexible
non-woven composite includes controlled adhesive content for optimized
adhesive control. In an exemplary embodiment using either a non-W/B
adhesive or a W/B adhesive, the adhesive content of the flexible
non-woven composite is of sufficient amount to adhere to other layers but
not a sufficient amount to form a continuous layer. Described another
way, the amount of resin adhesive on the flexible non-woven composite
does not cover the "windows" in the fiber layers but instead leaves the
desired gap. The amount of controlled adhesive applied in each material
is dependent on the characteristics of the material layers. Some
materials need more adhesive to create a bond in comparison to other
materials.

[0027] In another exemplary embodiment, a W/B adhesive is used to bond the
materials and the W/B adhesive may cover the "windows" while maintaining
the breathable functionality of the material. For example, FIG. 5
references an embodiment of a non-W/B polymer 501 coating the filaments
502 and a W/B polymer 503 filling the empty spaces or windows.
Furthermore, in one embodiment and with reference to FIG. 6, a non-W/B
polymer 601 coats the filaments 602, a W/B polymer 603 fills the empty
spaces or windows, and a W/B membrane 604 is bonded to W/B polymer 603.
FIG. 7 illustrates an embodiment having filaments 702 embedded in a W/B
polymer 703. Additionally, FIG. 8 references an embodiment having
filaments 802 embedded in a W/B polymer 803 and also bonded to a W/B
membrane 804. The embodiments referenced in FIGS. 5, 6, 7, and 8 may
include other layers of coated fibers, W/B membranes, woven fabrics or
other suitable materials. FIGS. 9 and 10 are examples of such embodiments
that include multiple layers.

[0028] In an exemplary embodiment and with reference to FIG. 9, a
multidirectional reinforced W/B material 900 comprises fibers 902
embedded in a W/B polymer 903. Multiple layers of fibers 902 and W/B
polymer 903 are stacked at designed orientations of 0°,
90°, +45°, and -45° relative to an axis in a
membrane layer. Moreover, FIG. 10 references an embodiment of a
multidirectional reinforced W/B material 1000 comprising fibers 1002
embedded in a W/B polymer 1003 and also bonded to a W/B membrane 1004.
Similar to multidirectional reinforced W/B material 900, multidirectional
reinforced W/B material 1000 comprises multiple layers of fibers 902 and
W/B polymer 903 stacked at designed orientations of 0°,
90°, +45°, and -45° relative to an axis in a
membrane layer. One example of a suitable W/B adhesive is thermoplastic
polyurethane (TPU) but other materials are also suitable.

[0029] Additional details with regards to material, process, methods and
manufacturing, refer to U.S. Pat. No. 5,470,632, entitled "COMPOSITE
MATERIAL FOR FABRICATION OF SAILS AND OTHER ARTICLES," which was issued
on Nov. 28, 1995, and U.S. Pat. No. 5,333,568, entitled "MATERIAL FOR THE
FABRICATION OF SAILS," which was issued on Aug. 2, 1994; the contents of
which are hereby incorporated by reference for any purpose in their
entirety.

[0030] Benefits, other advantages, and solutions to problems have been
described above with regard to specific embodiments. However, the
benefits, advantages, solutions to problems, and any element(s) that may
cause any benefit, advantage, or solution to occur or become more
pronounced are not to be construed as critical, required, or essential
features or elements of any or all the claims. As used herein, the terms
"includes," "including," "comprises," "comprising," or any other
variation thereof, are intended to cover a non-exclusive inclusion, such
that a process, method, article, or apparatus that comprises a list of
elements does not include only those elements but may include other
elements not expressly listed or inherent to such process, method,
article, or apparatus. Further, no element described herein is required
for the practice of the invention unless expressly described as
"essential" or "critical."